Method of forming domed buttons



Aug. 13, 1940 P. E. FENTON ET AL 2,211,322

METHOD OF FORMING DOMED BUTTONS Filed March 25, 1937 mw/f`\ 2 muni gg W Sw Smm @lm/Mem? ATTORNEYS Patented Aug. 13, 1940 UNITED STATES METHOD OF FORMING DOMED EUTTGNS Paul E. Fenton, Thomaston, and Edmund D. Janes, Middlebury, Conn., assignors to Scovill Manufacturing Company, Waterbury, Conn., a corporation of Connecticut Application March 25, 1937, Serial No. 133,018

8 Claims.

The present invention relates to a new method for manufacturing tack, or staple, attached metallic buttons, and in its more particular aspects, to improvements in the buttons themselves and 5 in the apparatus for carrying out the method.

These buttons are generally made in two styles which are not dilerentiatable by any utilitarian quality but only in so far as the filat style has a flat cover and supporting filler, whereas the comparable parts for the domed style are of spherical proportions.

According to presently known methods, each style is assembled from parts individual to it, thus necessitating the stocking of two complete lines of parts, with corresponding carrying charges. Further, the assembly of the domed style is somewhat more expensive and troublesome than that of the flat style, for with the former buttons the convex filler must be fed through its feed channel in proper relation to the feeding of the convex cover, so that when these parts meet at the point of assembly their faces will be disposed in matching relation. Frequently one of the fillers comes through the assembling machine in an upside down position and the machine must then be stopped while the spoiled button is removed.

The principal object of the invention is to provide a new method of manufacture wherein a standard flat ller may be used as an assembly part for either a iiat or a domed style button so as to avoid the above-mentioned problems incident to the feeding of convex llers, and to reduce the number of different parts which must be stocked for manufacturing both styles according to presently known methods.

It is another object of the present invention to provide a method wherein the initially flat nller element comprising a part of a domed but- 40 ton in accordance with the foregoing, may be upset so as to conform to the shape of and support the domed cover element subsequent to the operation wherein the button parts are assembled and closed.

It is a further object of the invention to provide a method and apparatus wherein a domed button may be assembled from parts now used exclusively for the iiat style so as to avoid the necessityT for stocking two lines of parts; and wherein the cover and filler elements of the button may be upset and given a desired shape subsequent to the assembling of the button so as to avoid troubles incident to the feeding of con- Vex parts.

55 The full nature and various other advantages vto' be obtained from the present invention will be more apparent from the following description, when read in connection with the accompanying drawing, in which:

Figure 1 is an elevational view of the various elements which go into the manufacture of a conventional tack-attached metallic button, certain parts `of some of these elements being broken away better to show the interior construction thereof.

Fig. 2 shows the button parts of Fig. 1 in assembled relation, with certain parts broken away, and disposed between a pair of oppositely arranged closing dies.

Fig. 3 is a sectional view of the parts of Fig. 2 after the die elements thereof have been brought together to achieve a closing of the button.

Fig. 4 is a sectional View of the assembled button taken on the line 4 4 of Fig. 2.

Fig. 5 is an elevational view, partly in section, of a button disposed upon a sheet of supporting material in proper relation to a conventional attaching tack, and a pair of dies for supporting these elements and driving the tack through the material to attach the button to the latter.

Fig. 6 is a like View of the parts of Fig. 5 after the die elements have been brought together to effect the attachment of a button to its supporting sheet.

Fig. 7 is a sectional view of a partly completed, domed style of button which h'as been assembled from a preformed dome cap, a flat supporting filler, and the usual back and collet elements.

Fig. 8 is an elevational View, partly in section, illustrating a part of the operation wherein the button of Fig. 7 is attach-ed to its supporting sheet, and the iiller element upset to complete the button.

Fig. 9 is an elevational view of a conventional flat metallic button.

Fig. 10 is an elevational view of domed style button, attached to its supporting sheet, after removal from the dies of Fig. 6.

Fig. 1l is a plan view of the button of Fig. 7 after attachment to its supporting sheet of material, as partly illustrated in Fig. 8.

The assembly parts for a conventional metallic tack-attached button, of the hat style, are illustrated separately in Fig. l, and comprise a back ifi, a collet il, an anvil or ller l2, and a y cover E3. Usually the back is drawn, pressed and otherwise worked from a single sheet o1 relatively thin sheet metal so as to have a hub iii with a central tack opening l5 therein, a cylindrical shank l@ of such proportions as to receive the cylindrical collet il with the central openings il of the latter axially aligned with the opening in the hub, a radially extending flange l 8 and an outwardly and forwardly turned marginal rim i9 defining a recess for the anvil l whence it may later be turned inwardly over this rim to secure the parts together.

These various button parts, in assembled relation, are shown in Fig. 2 disposed upon a supporting anvil 22 with the front face of the cover resting upon the seat 23. If this seat be of flat proportions, then on the closing of the die 24 over the back and over the edges of the flange 2|, the at style button illustrated in Fig. 9 will be produced. If, on the other hand, it is desired to make a concave button from these fiat parts, then the seat 23 will be concaved to some extent, as illustrated.

The closing die 24 illustrated in Fig. 2 has a central opening 25 of such proportions as to be capable of receiving the shank I6 of the button; a face 26 immediately surrounding the opening and cut back to such extent that the salient 21 formed by the juncture of the cylindrical wall defining the opening 25 with this face 2S will engage the back flange i8 only along the line at which this back flange meets the shank I 6; and a forwardly and outwardly extending surface 2S of such proportions and angularity as to be capable, when the die is brought downwardly over the button (Fig. 3), of engaging the flange 2l of the cover and forcing it progressively inwardly so as to engage the rim of the back. At the same time the drawing of the cover incident to this closing, plus the pressure exerted by the salient on the back and transmitted through the back and ller to the cover, will force the face of the latter to assume the concave shape of the die.

When the dies 22 and 24 are retracted, and the button removed therefrom, it will be noted that its front face has a convex shape but that its filler element still retains its initial flat charn acter. While such a button might be considered suitable for commercial use, it is evident that the flat filler is perfectly free to rattle around,

and that the rather thin, unsupported face of this button would soon become dented, and, in fact, might be pushed inwardly to such extent as to loosen the engagement between the flange 2| and the rim I9. Further, the radius of curvature of this cover is somewhat less than is usually considered desirable.

'Ihe next step in the method, then, is to upset the filler, and at the same time further shape the cap. In accordance with the present inven tion this is performed during the operation wherein the button is attached to a sheet of supporting material. In such an operation (Figs. 5 and 6) the button generally designated 29 is placed upon a sheet of material 3D with its hub engaging one surface thereof; and a conventional tack 3l is placed on the other side of the sheet with its pointed prong 32 in axial alignment with the tack opening l5 in the hub, and with its head 33 supported upon a suitable anvil 34. The attaching die 35, as may be seen in Fig. 5, has a seat 36 concaved on a radius which is somewhat less than the radius of curvature of the cap of the button. Hence when this die is brought downwardly to the position illustrated in dotted lines in Fig. 5, its seat will engage the button only along the outer edges of the cover, and its center portion and the center portion of the flat ller will be entirely unsupported; and when it is driven further downwardly, the pointed prong 32 of the tack will engage the unsupported center of the anvil and upset the latter and the face of the cap, so that they completely fill the die. Thereafter, since all parts of the cover and filler are now supported by the seat 36 of the die, the end of the prong will turn over, as illustrated in Fig. 6, so as to clinch within the button and result in a firm attachment of the button to its supporting sheet 30. Simultaneously, of course, the flange I8 of the back will be upset so as to engage the upset part of the filler, as shown in Fig. 6.

So far, in manufacturing a domed button from the flat parts illustrated in Fig. 1, best results have been obtained by this two step process, that is, by upsetting the cap to a certain extent during the closing of the button parts while leaving the anvil perfectly flat, and then further upsetting the cap and completely upsetting the filler by supporting the button at its edge portions while driving a pointed tack against its unsupported center portions. Accordingly, when this method is practiced, only one stock of assembly parts need be maintained, since either fiat or domed buttons may be made therefrom; and all of the problems incident to the feeding of domed fillers in proper relationship to domed caps during assembling operations are completely avoided.

In many instances the button cap is stamped or embossed, during manufacture, of course, with an ornamental design, or with a trade-mark; and the design portion is usually treated with paint so that it will stand out in bold relief. In such cases, the shaping of the cap to form a domed button in the manner above described is undesirable, for the drawing of the front surface thereof may distort the design, and crack the paint.

A modified form of the invention, particularly applicable to such cases, is illustrated in Figs. "I, 8 and 11. Here the button is assembled from the back I9, collet H, and ller l2 of Fig. 1, with a standard domed type cover 37 such as is presently used in making the dome style of but- 1 tons. The latter element comprises nothing more than a single piece of thin sheet metal, pressed and drawn in accordance with well known practices, so as to have a front face 20a of desired convex curvature with a suitable design 38 stamped or embossed thereon, and a rearwardly extending flange Zla of such proportions as to t easily over the rim I9 of the back. These parts may, of course, be assembled in presently available standard machines, but it is to be noted that the use of the flat filler completely avoids the necessity for feeding that element in any particular relation to the cap; and, accordingly, the necessity for the special feeding elements now incorporated in such machines to guide the presently used convex fillers. After assembly, the parts are squeezed between a pair of closing dies (identical with those of Figs. 2 and 3 except insofar as the curvature of the seat 23 is changed to conform to the curvature of the cover 31) to close the flange Zia over the rim I9.

While the button of Fig. '7 has a desired shape, and presents a desired appearance, it is not in condition for ordinary commercial usage because its filler element is still fiat and hence provides no support for the front face of the cover. In this condition, then, the button is termed partially completed; and it is completed during the operation wherein it is attached to a sheet of supporting material exactly as was described in connection with Figs. 5 and 6, and as further illustrated in Fig. 8. Here the die 35a (similar to die 35 except insofar as its face 36a may require modification to accommodate the design on the bil cover) engages the entire surface of the cover 3l as it descends, but the filler l2 is supported only along its edges. Hence, when the unsupported center of the ller engages the pointed prong of the tack, it will be upset, the prong will be clinched, and the iiange i8 of the back will be upset exactly as is shown in Fig. 6, and as hereinbefore described.

The degree of curvature of the domed cover is to some extent variable; and depends in large part upon the use to which the button is to be put, and to the whim of the individual user. This being' true, it is evident that the foregoing methods may be further modified to reduce the number of stocks of parts, and hence the nal cost. Thus, for example, the button may be assembled from a cover having an initial contour comparable to that shown in Fig. 5 and such a button may then be further shaped during the attaching operation. Consequently, it will be seen that a Very few standard lines may be made to serve the needs of a large assortment of customers.

The invention has so far been described and Shown only in connection with the manufacture of a metallic button adapted to be attached to a supporting sheet by means of a single pronged tack. Obviously, of course, it is equally and fully applicable to cases wherein the button is attached by means of a well known two-pointed staple. In such case the button will be assembled from conventional back parts, too well known to require description, with an anvil i2 and cover i3 (or 3i) of the type disclosed in Figs. l and 7; closed exactly as was described in connection with Figs. l and 3; and attached to a supporting sheet in exact accordance with the method shown in Figs. 5, 6 and 8. Of course, since the staple will have two prongs rather than a single one, it is evident that the points of these prongs will not engage the mathematical center of the filler element, but they will engage the central, unsupported portion of this filler to upset it in the desired manner.

Since certain changes may be made in the invention without in any way departing from the true scope thereof, it is intended that the foregoing shall be construed in a descriptive rather than in a limiting sense. l

What we claim is:

1. The method of dorning a tack button or the like of the type comprising a back element having a hollow cylindrical shank and a radial flange at the inner end thereof, a cover locked with the periphery of the flange, and a substantially at filler disposed between the cover and the flange of the back, in the act of attaching such button to supporting sheet material by means of 'a tack of the type having a head and a pointed prong, which method comprises interposing the sheet material between the free end of the shank of the button back and the pointed end of the prong of the tack, supporting the button along the outer face of its cover in such manner as to lend support to the flat filler element only adjacent its periphery, driving the tack through the sheet material and against the rear surface of the 'lat ller to deform the unsupported central portion thereof, limiting the deformation of the filler, and continuing to drive the tack against the filler whereby to turn its free end and clinch it within the button.

2. The method of doming a tack button according to claim 1, further characterized by controlling the nal contour of the cover of the button during the step wherein the deformation 4. The method of oloming a button according to claim l further characterized in that the cover of the button is initially of convex contour but on a radius which is greater than that desired in the final button; in that such cover is supported only adjacent its periphery whereby to leave both its central portion and the central portion of the filler unsupported; in that the driving of the tack against the ller deforrns both the filler and the cover; and in the further step of controlling the final contour of the cover during the step wherein the extent of its deformation is limited.

5. The method of doming a tack button accordto claim l further characterized in that the button cover is initially of desired contour; in that such cover is supported along its entire front surface; in that such support limitsl the deformation. of the filler and prevents deformation of the cover; and in that the flange or the back element is also deformed during the tack driving operation.

6. The method of doming a button according to claim l further characterized in that the driving of the tack against the filler is continued until its head engages the sheet material and applies a force to the end of the shank sufficient to deform the ange of the back into engagement with the rear surface of the ller.

7. The method of dorning a tack button according to claim l further characterized in that the button cover is initially of desired contour; in that such cover is supported along its entire front surface; in that such support limits deformation of the filler and prevents deformation of the cover; and in that the driving of the tack is continued until its head engages the sheet material and applies a force to the end of the shank sufficient to reform the flange of the back element into engagement with the rear surface of the filler.

8. The method of forming a domed button from a partially completed one comprising a back element having a hollow cylindrical shank and a radial flange at one end thereof, a cover locked with the periphery of the flange, and a substantially flat iiller disposed between the cover and the flange of the back, which method comprises the steps of supporting the button along the outer face of its cover in such manner as to lend support to the flat ller only adjacent its periphery, driving an implement through the shank of the button against the unsupported central portion of the rear surface of the ller whereby to deform such filler, applying a force to the end of the shank of the button whereby to deform the flange of the back, and limiting such deformation of the ller while controlling the contour of the cover.

PAUL E. FENTON. EDMUND D. JANES. 

